BRAUMAT®: Recipe based Control System for Brewing and Malting

Introduction to BRAUMAT®

BRAUMAT® is a SCADA-based recipe control system designed for the brewing and malting industries. It provides advanced automation capabilities for batch processes, ensuring efficiency, reliability, and flexibility.

Visual: A laptop displaying the BRAUMAT software interface alongside a beer can.

Addressing Industry Challenges

BRAUMAT® helps breweries and malt houses overcome key challenges:

• Increasing complexity of operation
• Demand for process transparency
• Faster and flexible adaptation of recipes
• Reduction of manual and routine work
• Investment protection and future-proofness
• Fast support and maintenance

BRAUMAT® System Overview

As a SCADA-based process control system, BRAUMAT® offers:

• Recipe controlled processes
• Batch based operations (ISA88)
• Management of complex silo or tank material transfers
• Multiple reporting options
• Seamless scalability
• IT/OT Integration
• Future investment protection

BRAUMAT® acts as a crucial layer between Distributed Control Systems (DCS) and Supervisory Control and Data Acquisition (SCADA) systems, leveraging SCADA-based technology for comprehensive control system functionality.

Visual: A pyramid diagram illustrating BRAUMAT's position between DCS and SCADA, alongside SIMATIC PCS 7/PCS neo and SIMATIC WinCC.

Comprehensive Siemens Portfolio Integration

BRAUMAT® is part of a comprehensive Siemens portfolio, integrating seamlessly with:

• Enterprise Level: Mindsphere Cloud services, ERP integration.
• Plant Management: Opcenter suite (Intelligence Suite, Execution Process, RD&L, APS), Energy Management (SIMATIC Energy Suite).
• Control Room & Plant Engineering: SIMATIC TIA portal, BRAUMAT Engineering, Simulation, BRAUMAT Operating System, SIMATIC WinCC, SIMATIC HMI.
• Field Level: PROFINET, PROFIBUS, Industrial Communication (SCALANCE), SIMATIC Distributed I/O, SIMATIC Field Bus, SIMATIC Ident, SITRANS Instrumentation, SIWAREX Weighing, SINAMICS Drive applications.
• Controllers: BRAUMAT PCU Controller, SIMATIC S7-1500, SIMATIC S7-400, SIMATIC OpenController.

Visual: A layered diagram showing the Siemens portfolio for batch processing, from Enterprise down to Field level, listing various software and hardware components.

Key Functionalities and Benefits

Recipe Controlled Automation

BRAUMAT® enables recipe-controlled automation for batch-based production, offering:

• Easy operation of processes.
• Efficient training: One person can be trained in 5 days to engineer and operate the entire system.
• Flexibility: Modifications are possible in running processes with very short turnaround times.
• Proven history: Over 45 years of successful implementation, originating in the brewing industry.
• Multi-language support: Available in English, German, Spanish, Chinese, French, Portuguese, and Polish, with other languages as an option.

Graphical Recipe/Batch Control

Provides transparent process monitoring with features such as:

• Status of the process always under control.
• Active step highlighted with its number.
• Out-of-the-box synchronization between units.
• Step-related parameter visibility.
• Immediate access from process image or unit overview.
• Easy comparison of current online parameters with setpoints.
• Relevant process information including interlock status, updated and visible online.

Visual: A detailed screenshot of the BRAUMAT interface showcasing graphical recipe/batch control, highlighting active steps and displaying parameters.

Process Data Recording with Replay Mode

The Replay Mode allows displaying historical process data with the look and feel of an interactive video, offering:

• Visualization of historical production data.
• Easy error root cause detection and analysis.
• Operator training using past production scenarios.
• An ideal basis for remote support and services.

Visual: A screenshot of the BRAUMAT Replay Mode interface, demonstrating historical data visualization with a timeline and process diagram.

Integrated Maintenance Support

Enhances maintenance processes with:

• Time-based customized Maintenance Reports.
• Maintenance Supervising via ICM and user aggregates.
• Maintenance Groups for secure closure of line sections.
• User-defined setpoints to launch maintenance messages.

Visual: A table detailing maintenance report data and a list of ICMs with their respective switch counts.

Route Control System

Manages transfers with plausibility checks, featuring:

• Automated transfers of different materials, including CIP (Clean-in-Place).
• Planning based on preconfigured partial routes.
• Key functionality for state-of-the-art silo and tank farm automation.
• Dynamic and constraint-based search for paths between source and destination.
• Graphical Route Viewer for enhanced transparency.

Visual: A photograph of industrial piping and equipment in a brewery, with text overlay describing the Route Control System.

BRAUMAT and Opcenter Execution Process Integration

Offers a strong value proposition for breweries and malt houses through:

• Integrated execution of batch-based operation (ISA 88.1) into MOM (ISA 95) workflows.
• Out-of-the-box interplay between Opcenter and BRAUMAT.
• MOM-based global manufacturing templates that can include the BRAUMAT system.
• Deployability in MOM multiplant scenarios, combining security, usability, and robustness.

Visual: A photograph of a brewer holding a glass of beer, with text overlay highlighting the value proposition of BRAUMAT and Opcenter.

Energy Efficiency with SIMATIC Energy Suite

Improves energy efficiency by providing:

• Energy transparency for each process step, unit, and procedure, in accordance with ISO 50001.
• Batch-based energy reporting to understand energy costs.
• Avoidance of expensive energy peaks through load management.
• Optimization of energy consumption using the SIMATIC Energy Manager.

Visual: A table and a bar chart illustrating energy consumption values (kWh) for different process steps.

BRAUMAT LEAN Edition

The entry-level solution for streamlined automation:

• Designed for 1 PCU and 1 Server configurations.
• Offers pricing comparable to a small SCADA system but with full process control functionality and a batch engine.
• Corner points: Additional operator clients can be added anytime, Replay mode is integrated, and it can be seamlessly upgraded to BRAUMAT Full Edition.

Visual: A screenshot of the BRAUMAT LEAN edition interface and a photograph of a Siemens industrial PC/controller.

Web Monitoring & Mobile Solutions

Enables continuous process tracking, even under mobile conditions:

• Provides basic on-board functions like events and alarms.
• Optional notifications via E-Mail, SMS, pager, or printer, including a dashboard for analysis.
• Optional escalating alarms via predefined participants or operators.
• Flexible process screens based on HTML5.

Visual: A screenshot of a mobile device displaying the BRAUMAT mobile solution interface.

Safety Functionality

Prioritizes safety with BRAUMAT Safety first:

• Prevents harm to staff (e.g., in manholes, mills, motors).
• Helps to avoid spoiled food.
• Features the CPU S7-1518HF as a safety edition, suitable for mixed configurations.
• Can be seamlessly integrated into existing BRAUMAT installations.

Visual: An image symbolizing safety, showing a person wearing augmented reality glasses with digital overlays.

Cybersecurity and Safety Functionality

Ensures robust security for industrial operations:

• BRAUMAT Cybersecurity: PCU protection via hardware-protected password security, terminal bus security against man-in-the-middle attacks, optional operator station security via RFID card, and Hot-Standby PCU for emergency plans.
• Industrial Cybersecurity Services: Includes Plant Security Services (IEC 62443 assessments & consulting), Network Security Services (Firewalls, DMZ, Anomaly Detection), and System Integrity Services (Endpoint Protection, Vulnerability & Patch Management, Backup & Restore).

Visual: A diagram illustrating cybersecurity layers (Plant, Network, System Integrity) and a Siemens RFID card.

Solution Offering

Siemens offers comprehensive solutions to ensure success:

• 360-degree process automation consulting focused on plant operation efficiency and sustainability.
• Tool-based standardization for each project phase with defined project documentation.
• Cyber-secured remote services are available.
• Extensive experience from numerous Brownfield or Greenfield plant projects worldwide since 1977.

Visual: An image depicting various consumer products (soda, milk, chocolate, sugar, soap) alongside industrial plant silhouettes, symbolizing BRAUMAT's application across industries.

BRAUMAT / SISTAR V8.0 SP2 Features

Overview

BRAUMAT / SISTAR V8.0 Service Pack 2 represents the next step in process control development for Food & Beverage and similar industries. It introduces new innovations while maintaining proven features, focusing on increased reliability, flexibility, and usability for more intuitive and efficient batch-based operation. Key technical features include enhanced hardware capabilities, improved route control usability, and better connectivity to the MES layer.

Supported Systems

Automation Systems (PLC):

• S7-1500 series (e.g., CPU 1518-4 PN/DP, CPU 1516-3 PN/DP, CPU 1518-4F PN/DP, CPU 1516-3F PN/DP, CPU 1505S/F, CPU 1507S/F, CPU 1508S/F, and new CPUs like 1517-3 PN/DP, 1517-3F PN/DP, 1518HF-4 PN).
• S7-400 series (preferential range, e.g., CPU 417-4, CPU 416-3 PN/DP, CPU 416-3).

Supported Operating Systems:

• Windows 7 (Ultimate/Enterprise SP1 64Bit)
• Windows 10 (Enterprise 2015 LTSB, 2016 LTSB, LTSC 2019 64Bit)
• Windows Server (2008 R2 SP1, 2012 R2, 2016, 2019 64Bit)
• Windows Embedded Standard 7 SP1 (32Bit)

Platforms for Virtualization:

• VMware ESX
• Microsoft Hyper-V

Visual: Images of Siemens S7-1500 and S7-400 PLC hardware.

New Features and Enhancements

• High Availability PLC: Increased production availability with support for S7-1518HF CPU, featuring hot-standby with fast fail-over.
• Conveyor Control: Enables control and monitoring of conveyor lines for solid materials, supporting sequential start-up/stop and complex interlinked setups.
• Graphical Route Viewer: Offers support for engineering and verification of complex Route Control configurations through route graph representation.
• Higher Flexibility for Lean: Introduction of smaller extension licenses (by +4 Units) for smoother expansion, especially for smaller configurations.
• Integrated Connectivity to Opcenter Execution Process: Provides out-of-the-box interplay between IT and OT levels, reducing integration effort and costs.
• Extended Language Support: New operator languages including French, Polish, and Portuguese are available via easy integration of language packs.

Visual: Diagrams and screenshots illustrating high availability PLC setup, Graphical Route viewer, Opcenter architecture, conveyor control interface, license concept graph, and language selection screen.

Partner Support

Siemens offers 3rd party support through certified partners who are audited and certified as BRAUMAT/SISTAR Experts. These partners provide proven services, consulting, project management, and quality management, backed by continuous training and support from Siemens.

Find your BRAUMAT expert using the Siemens Industry Partner Finder.

Visual: An image of a compass on a map, symbolizing the search for expert partners.

BRAUMAT®: Beer Simply Brewed Better

Visit siemens.com/BRAUMAT for more information.

Visual: A laptop displaying the BRAUMAT interface, a beer can, a QR code, and the website URL.

Disclaimer

© Siemens 2022. Subject to changes and errors. The information provided contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. Requested performance features are binding only when expressly agreed upon in the concluded contract. All product designations may be trademarks or other rights of Siemens AG, its affiliated companies or other companies whose use by third parties for their own purposes could violate the rights of the respective owner.